Graco PRO 3500hc - Manuals

6 308018 Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun. Part of theair operates the turbine and the rest of the air atomizesthe fluid being sprayed. The turbine generates power,which is converted by the power cartridge, to supplyhigh voltage curren...

8 308018 Installation KEY A Main Air Supply Line B* Ventilation Fan Interlock Solenoid ValveC* Main Air Supply Shutoff Valve (bleed-type) D Air & Water Separator E* Pump Air Supply Shutoff Valve (bleed-type) F Air Line Lubricator G Air Pressure Regulator H Pump J* Pump Ground Wire K Fluid Filter...

308018 9 Installation Installing the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause electric shock or other seriousinjury if work is not performed properly. Do not install or service this equip-ment unless you a...

10 308018 Installation Connect the Exhaust Tube Press the exhaust tube (provided) onto the barbedadapter on the bottom of the gun handle. Secure thetube with the clamp provided. Refer to page 36. Connect the Fluid Line (Refer to Fig. 1) 1. Before connecting the fluid line (N), blow it out withair an...

308018 11 Installation Check the Electrical Grounding (See Fig. 2) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDMegohmmeter P/N 241079 (AA-see Fig.2) is not approved for use in a hazard-ous area. To reduce the risk of sparking,do not use the megohmmeter to checkelectrical grounding unless: The ...

308018 13 Operation Pressure Relief Procedure WARNING PRESSURIZED EQUIPMENT HAZARDThe system pressure must be manually relieved toprevent the system from starting or spraying acci-dentally. To reduce the risk of an injury from electricshock, accidental spray from the gun, splashingfluid, or moving p...

14 308018 Operation 05151A Fig. 4 06615 20 1 26 45 43 31 DD Selecting a Fluid Nozzle and Air Cap WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 13 before removing orinstalling a fluid nozzle and/or air cap. The gun is supplied with a ...

16 308018 Operation Shutdown WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 13 whenever you stopspraying and whenever you are instructed torelieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc...

308018 17 Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spraytip holes as this could scratch them, and make surethe electrode wire is not damaged. Scratches in theair cap or spray tip or a damaged electrode wire candistort the spray pattern. Eq...

18 308018 Troubleshooting WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause an electric shock or other serious injury if the work is not performed properly. Do notinstall or service this equipment unless you aretrained and qualified. WARNING ...

308018 19 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packingarea The needle packings or shaft are worn. Replace the packings or shaft; see page28. The packing nut is loose Tighten the packing nut; see page 28. Air leakage from the front of the g...

20 308018 Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap-around The ES ON-OFF lever is in the OFF (O)position.* Turn the lever to ON (1). The distance between the gun and work-piece is incorrect. Adjust the spraying distance to 8 to 12 inches(203 to 305 mm) The parts are...

308018 21 Electrical Tests The performance and safety of the spray gun aredirectly affected by the condition of the electricalcomponents contained inside the gun. The electricaltests below can be used to determine the condition ofthe power supply (18) and the resistor stud (22) as wellas the continu...

22 308018 Electrical Tests Test Power Supply Resistance Remove the power cartridge (18) from the gun handle.See Power Cartridge Replacement on page 29. Remove the turbine alternator from the power car-tridge. See Turbine Alternator Removal on page 30. Measure the resistance from the power supply’sgr...

308018 23 Electrical Tests Test Resistor Stud Resistance (continued) If the resistance is outside the specified range, removethe resistor stud (22). See Air Cap/Nozzle/ResistorStud Replacement on page 24. Check the resistancebetween the black resistor stud contact ring (D) andthe needle contact ring...

24 308018 Service Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts that may causeelectric shock or other serious injury if the work is not performed properly. Do not install orservice this equipment unless you are trained andqua...

308018 25 Service Air Cap/Nozzle/Resistor StudReplacement (continued) 6. Trigger the gun while installing the fluid nozzle (21)and resistor stud (22) assembly with the multi-tool(62). Tighten until the fluid nozzle seats in the gunbarrel. 7. Install the air cap assembly (1, 2, 8). Test the gunresist...

26 308018 Service Barrel Removal 1. Prepare the gun for service as instructed on page24. 2. Carefully loosen the nut (14) from the bracket/fluidfitting (16). Pull the tube (12) out of the fitting.Make sure both ferrules and the nut stay with thetube. See Fig. 14. 3. Using the wrench (63) supplied, l...

308018 27 Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page24. 2. Remove the air cap assembly, fluid nozzle andresistor stud, and electrode as instructed on page25. 3. Loosen the trigger screws (4) far enough to re-move the trigger (13). 4. Remove the packing cartrid...

28 308018 Service Fluid Packing and Needle Repair The fluid packings and needle can be replaced asindividual parts or as assemblies. The overall assem-bly is pre-adjusted at the factory. NOTE: Before installing the packing and needle as-sembly into the gun barrel, make sure the internalsurfaces of t...

308018 29 Service 06629 Fig. 18 7 35 37a 37b 18b 18c 18a 18 18d 37 F Apply a very light coat of lubricant Do not expose to solvents Power Cartridge Replacement NOTE: The power cartridge consists of the alternator(37), power supply (18) and retaining ring (35). SeeFig. 18. 1. Prepare the gun for serv...

30 308018 Service Turbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours ofoperation. See your authorized Graco distributor. 1. Prepare the gun for service as instructed on page24. 2. Remove the power cartridge from the gun handleas instructed on page 29. 3. Squeeze the two ...

308018 31 Service Fan Air Adjustment Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Place a wrench on the flats of the valve housingand remove it from the handle. See Fig. 20. NOTE: The fan air valve (43) can be replaced as anassembly or as individual parts. To disassemble t...

32 308018 Service Fluid Adjustment Assembly Repair 1. Prepare the gun for service as instructed on page24. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45). See Fig. 21. 3. Turn the stem (45a) fully clockwise and removethe sleeve stop (45e). 4. To completely disassemble the f...

308018 33 Service Air Trigger Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45), o-ring (23) and spring(44). See Fig. 21. CAUTION Clean all parts in non-conductive solvent compatiblewith the fluid being used,...

34 308018 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Loosen the set screw (24) with the 2 mm hex key(69) provided. Remove the lever (26) from thevalve. See Fig. 23. WARNING MOVING PARTS HAZARDTo reduce the risk of eye injury, be sureto wear safety glass...

308018 35 Service Tube and Shroud Removal/Replacement 1. Prepare the gun for service as instructed on page24. 2. Remove the air cap, nozzle and resistor stud, andelectrode as instructed on page 29. 3. Loosen the nut (14) and disconnect the fluid tube(12) from the bracket/fluid fitting (16). See theP...

36 308018 Parts 06614 6 7 4 13 3 1 8 2 22 20 21 25 35 34* 44 45d 23* 39 40 42* 66 17 15 19 33 12 10 24 26 36 47 32 31 12d 16 37a* 37b 18a* 18c 18b* 30 5 18d 19* See Detail A 67 28a 43b 43d 43e* 43c 18f 18e 12c REF. 16 12a 12b 12e DETAIL A 28g 28b 28d 28e 28f 28c 28h 46 38 41* 28 Item 12 includes ite...

308018 39 Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID;1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 6 ft (1.8 m) 218100 15 ft (...

308018 41 Technical Data Category Data Gun Weight 1.89 lb (0.86 kg) Gun Length 9.5 in. (240 mm) Maximum WorkingPressure 100 psi (7 bar, 0.7 MPa) Air PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Fluid PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Voltage Output 0–65 kV Paint Resist...